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August 9, 2012 A Penton Media Publication Tune in to EngineeringTV.com 200 mph and BATTERY POWERED page 20 FOCUS on ENERGY WILL NATURAL GAS POWER OUR CARS AND TRUCKS?, page 40 HOW TO MAKE PNEUMATICS MORE ENERGY EFFICIENT, page 44 ULTRACAPACITORS HOP UP MICROHYBRIDS, page 48 [ MOTOR TRUTH #13 ] Are you into belts and chains? If not, then you need SEW’s patented TorqLOC®. Its keyless hollow shaft and taper bushings eliminate inefficient belts, chains, and sprockets thus reducing maintenance and energy costs while enhancing system safety. Mounting Its spacious air gap provides easy mounting. Its tightening bolts provide easy dismounting. No more tight tolerances! No more keys! Need retrofit? No problem. TorqLOC even mounts onto an existing shaft that has a keyway. Visit sewmotortruth.com/truth13 for other ways to reduce energy. sewmotortruth.com/truth13 RS# 101 Dismounting !" ,":%,"$ A!% $ Compact Thermal Imagers OSXL-I3 (FLIR-i3)             !"# $% & '() *%' +%  ,% "$%  "%+ -.*/0% 123#"3 %#' $4 "' 5% %6&"7,"% $&$ $ !,8$ #0/##"' 9": $;:<  :"=" ® Powered By 6 >0 " % " % $ @ Visit omega.com/osxl-i_series Visit omega.com/video Digital Infrared Video Thermometer Compact Non-Contact Infrared Temperature Transmitter RTD Temperature Sensors with Micro-DIN Connectors 6 + 4 " % " % $@ .C " % " % $ 1 6 B0C $ Visit omega.com/os-vir50 Visit omega.com/pr-24 Visit omega.com/os151-usb   ® Νο. ® RS# 102 © COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED VOLUME 84 ISSUE 11 AUGUST 9, 2012 ENERGY EFFICIENCY Chrysler had already adapted several of its vehicles, including the Ram truck, to bifuel technology, letting them run on natural gas or gasoline. Such vehicles could help make the transition to vehicles predominantly powered by natural gas. FEATURES Should the U. S. switch to natural gas for transportation? motorcycle 20 Electric tops 200 mph Rocket, an electric dragster, set the quarter-mile record not only for electric motorcycles, but for all electric vehicles. The technology and gas is readily available. And it could save the U. S. over $200 billion annually. 40 MACHINE DESIGN.com Americans spend about $260 billion each year on oil from outside of NAFTA for transportation. This transfer of capital to other countries increases our national debt and interest load. Fortunately, analysis shows that we can quickly convert vehicles to domestic natural gas, which would let Americans remain mobile, keep the environment clean, and provide trillions of dollars over the next half century for developing alternative energy and transportation options for the long-term future. What the U. S. needs In terms of energy, the U. S. gets about 14.78 quads (1015 Btu) for its $260 billion. A trillion ft3 (Tcf) of natural gas contains approximately one quad. So 14.78 quads used for transportation per year can be replaced with 14.78 Tcf of natural AUGUST 9, 2012 Honda leases its hydrogenpowered FCX Clarity in California. Here is one at a hydrogen refueling station that gets it hydrogen direct from a pipeline. Standards are already in place to govern the safe operation of natural-gas fuel stations, like this one. Authored by: Dick Medvick Contributing Editor Cleveland, Ohio Edited by Stephen J. Mraz [email protected] For more on natural-gas vehicles, scan this code or go to: http:// machinedesign.com/ article/uneven-prospectsfor-natural-gasvehicles-0810 gas. That might seem like a lot of natural gas, but last year the U. S. Potential Gas Committee reported that the U. S. has at least 2,170 Tcf. America currently uses 23.37 quads from natural gas each year for residential, commercial, transportation, and industrial applications — either directly, or by generating electricity. Adding another 14.78 quads for transportation would push the total use to 38.15 quads per year, or 38.15 Tcf of natural gas. At this rate, 2,170 Tcf of natural gas would last a minimum of 57 years. In addition, Canada has at least another 780 Tcf of natural gas, the equivalent of another 20 years of gas use. So there’s plenty of natural gas, and converting transportation to it could save North American consumers $20 trillion ($260 billion annually for 77 years). That’s money that could fund research and development into new sources of safe and clean energy and transportation. Current NGV CSA America, the organization that writes standards for gas appliances and accessories and alternative-energy products, has already written standards for compressed natural-gas vehicles (NGV) and filling stations. The design work is done, and NGVs are in dealers’ showrooms. Honda, for example, sells NGVs which store natural gas at 3,600 psig. Other automobile manufacturers could quickly follow suit. And natural gas in its liquid form (LNG) is already becoming popular for long-haul trucking. It costs about $1.50 less for the equivalent of a gallon of diesel fuel, which can lead to significant savings for truckers routinely buying 20,000 gallons of diesel fuel annually. In fact, several truck and engine manufacturers offer LNG models, including Cummins-Westport, Kenworth, PACCAR-owned Peterbilt, Navistar, Freightliner, and Caterpillar. LNG trucks still cost more, but as more models are available, costs are coming down to the point many models pay back the price premium with the first year of savings on fuel. But there are problems with NGVs: Customers won’t buy them because there aren’t enough natural-gas filling stations and companies won’t install filling stations because there are not enough NGVs on the road. For truckers, this chicken-and-egg dilemma is being partly solved by an agreement between Clean Energy Fuels, a national natural gas supplier, and Pilot/Flying J truck stops. They plan to install refueling pumps at 150 locations along major interstate trucking routes by the end of next year, then add at least 100 more. The goal is to make it possible for an LNG truck to travel coast to coast and border to border — anywhere a diesel rig can go. For consumer cars and trucks, the solution to the fillingstation problem might be in the hands of the auto companies. They could design and sell bifuel vehicles, which run AUGUST 9, 2012 40 the U. S. switch 40 Should to natural gas for transportation? Switching to natural gas could end U. S. dependence on foreign oil for its transportation needs. ENERGY EFFICIENCY Getting ENERGY SAVINGS 44 from pneumatic systems Getting energy savings from pneumatic systems There are three basic ways to boost the efficiency of industrial pneumatics. There are three basic ways to boost the efficiency of industrial pneumatics. Industrial machines and production systems that are designed to run efficiently and save energy are undoubtedly important considerations in manufacturing today. The reasons not only include rising energy prices and the need to hold down production costs, but also an increasing awareness of the environmental impact on an organization’s sustainability. All of these issues should not simply be the responsibility of production-floor personnel. Machine and system designers and financial managers of industrial and manufacturing corporations have a stake in this as well. With pneumatic systems, there are basically three different ways to approach energy savings: leak detection, design, and advanced machine diagnostics. Here’s a closer look at each. Leak detection a cap in it! 48 Put The rapid charge and discharge ability of ultracapacitors opens a myriad of uses for quick and cleanenergy-storage needs. A good leakage-management program is essential. It radically lowers compressed-air consumption and the associated costs as leaks are a waste of compressed air, which translates into lost energy and money. In addition, leaks create pressure losses that can significantly slow production processes and prevent machines from running at peak capacity. A study by the Fraunhofer Institute in Germany looked at compressed-air systems in the European Union and concluded that 42% of the total potential savings in optimizing pneumatic systems comes from simply implementing a solid leak-detection program. The objective should be to completely check the pneumatic system from the compressor (supply side) to each machine and device (demand side). On the demand side, using a simple ultrasonic leak detector can help manually identify individual leaks on machines — usually for an entire The energy-efficient OVEM vacuum generator has an integrated filter and sensors that monitor the status of the vacuum system. 44 MACHINE DESIGN.com AUGUST 9, 2012 44 Access our Reader Service Web site to quickly find and request information on the products and services found in the pages of MACHINE DESIGN. www.machinedesign.com/rsc 2 MACHINE DESIGN.com AUGUST 9, 2012 MACHINE DESIGN.com 41 Bryant Watertight Wiring Devices ) ) ) ) Watertight devices need to work, so we offer the best - and at our everyday low direct prices. Rugged Bryant brand components are rated for those harsh conditions almost every process can experience. &% $#'$ &%!$(& "!&! %  &!"$ '"&!  "$& &"$&'$!&! $% &$&&!"!  &%%&$&&'%& Accepts #18/3 to #10/3 cord (#8/4 for 30A models) Keyed body and cover for proper alignment Closure cap seals out water and dirt when not in use Tongue and groove sealing system Strain relief compression cord seal with neoprene bushing Thermoplastic elastomer housing Transparent back for easy inspection of wired terminals Corrosion-resistant nickel plated blades and stainless steel captive assembly screws Double insulated elastomeric cover and thermoplastic body for extra safety and water resistance Cord Grips                              Also Available Wire Duct www.automationdirect.com/wiring-devices Field Wireable Connectors www.automationdirect.com Go online or call to get complete information, request your free catalog, or place an order. 1-800-633-0405 Cable Ties RS# 103 ON THE COVER Larry “Spiderman” McBride gets ready to drive the Rocket to its 200+ mph run. DEPARTMENTS 8 EDITORIAL Risk, benefits, and mental mistakes 10 EDITORIAL STAFF 12 LETTERS 16 SCANNING FOR IDEAS Rotary actuator increases speed, rotation, and response while cutting costs Gear drives reliably transmit power 20 28 35 36 REPORTER’S NOTEBOOK LOOKING BACK SENSOR SENSE COMMENTARY Two sides of a green-energy failure 38 VANTAGE POINT Educating the next generation of engineers — Sasha Gurke 39 INVENTOR’S CORNER 52 FE UPDATE Analysis helps subsea cables survive 55 SOFTWARE PRODUCTS 56 PRODUCT SPOTLIGHT Bearings & guides 57 60 61 62 62 63 PRODUCTS AD INDEX BUSINESS INDEX CLASSIFIEDS BUSINESS STAFF BACKTALK For customized article reprints and permissions please contact: Penton Reprints, 1-888-858-8851, e-mail at [email protected] or visit pentonreprints.com. Editorial content is indexed in the Applied Science Technology Index, the Engineering Index, SciSearch and Research Alert. Microfilm copies available from National Archive Publishing Company (NAPC), 300 N. Zeeb Rd., P.O. Box 998, Ann Arbor, MI 48106-0998, Ph: 734-302-6500 or 800-420-NAPC (6272), extension 6578. Permission to photocopy is granted for users registered with the Copyright Clearance Center (CCC) Inc. to photocopy any article, with the exception of those for which separate ownership is indicated on the first page of the article, provided that the base fee of $1.25 per copy of the article, plus $.60 per page is paid to CCC, 222 Rosewood Dr., Danvers, MA 01923 (Code No. 0024-9114/12 $1.25 + .60). Subscription Policy: MACHINE DESIGN is circulated to research, development, and design engineers primarily engaged in the design and manufacture of machinery, electrical/electronic equipment, and mechanical equipment. To obtain a complimentary subscription see our Web page at submag.com/sub/ mn. For change of address fill out a new qualification form at submag.com/sub/mn. Printed in U.S.A., Copyright © 2012. Penton Media, Inc. All rights reserved. MACHINE DESIGN (ISSN 0024-9114) is published semimonthly except for a single issue in January, February, June, July, and December by Penton Media, Inc., 9800 Metcalf Ave., Overland Park, KS 66212. Paid subscriptions include issues 1-18. Issue No. 19 (OEM Handbook and Supplier Directory) is available at additional cost. Rates: U.S.: one year, $139; two years, $199;. Canada/Mexico: one year, $159; two years, $239; All other countries: one year, $199; two years, $299. Cost for back issues are U.S. $10.00 per copy plus tax, Canada $15.00 per issue plus tax, and Int’l $20.00 per issue. Product Locator, $50.00 plus tax. Prepaid subscription: Penton Media (MACHINE DESIGN), P.O. Box 2100, Skokie IL 60076-7800. Periodicals Postage Paid at Shawnee Mission, Kans., and at additional mailing offices. Can GST #R126431964. Canadian Post Publications Mail Agreement No.40612608. Canada return address: Pitney Bowes, P.O. Box 25542, London, Ont., N6C 6B2. Digital subscription rates: U.S.: one year, $69; two years, $99;. Canada/Mexico: one year, $79; two years, $119; All other countries: one year, $99; two years, $149. 4 MACHINE DESIGN.com AUGUST 9, 2012 POSTMASTER: Send change of address notice to Customer Service, MACHINE DESIGN, P.O. Box 2100, Skokie, IL 60076-7800. Intelligent fans for smart savings. Most axial fans of the “compact class” use the old shaded-pole motor AC technology, despite its poor efficiency compared to DC technology. The barrier to improvement was that DC technology couldn’t be operated directly from the AC mains supply. A solution is now available with i-Maxx technology from ebm-papst. The i-Maxx retains the mounting dimensions of the equivalent AC fans and is capable of operating on AC mains power around the world. There is no simpler way to save energy. Learn more at info.ebmpapst.us/i-maxx the engineer’s choice RS# 104 What’s new online machinedesign.com FREE WEBCAST: APPLYING STEPPER MOTORS Thursday, August 9, 11:00 ET This Webinar, presented by ElectroCraft, will review basic parameters necessary to properly select and apply stepper motors to motion applications. The discussion will review stepper speed-torque behavior, thermal ratings, engineering calculations, and how windings impact dynamic behavior. Other topics will include considerations for intermittent-duty operation, motor/system accuracy, failure modes, and how to apply these criteria to stepper-based linear actuators. Learn more and register at http://tinyurl.com/d9bfkk9. Hydraulic-powered go-cart Hennepin Technical College is teaching students about fluidpower technology and making it fun, too. An instructor shows off a go-cart powered by fist-sized, 5-hp hydraulic motors that eliminate gears, clutches, chains, and belts. He also discusses a mobile picnic table with a hydrostatic drive, a hydraulic motorcycle, and a pneumatic lawnmower. View the episode at www.engineeringtv.com/video/ Hydraulic-Fun-and-TeachingFlui;Fluid-Power-Conference-Expo-201. EDITOR’S WEB PICKS Power-transmission site 6 U. S. Tsubaki has launched a new Web site (http://ustsubaki.com) on its roller chains, motion-control components, sprockets, and other products for the energy, mining, foodprocessing, forestry, packaging, and conveyor markets. Content includes detailed specs and images, videos, and a library of 2D and 3D CAD drawings. Users can compare similar products by characteristics such as dimensions, materials, and specific features. And an online configurator lets users create complex drawings on demand. Wireless Web site The new Linx Technologies Web site (www.linxtechnologies.com) covers wireless products such as RF modules, remote controls, antennas, connectors, and development kits. Content includes specs, documentation, application notes, and FAQs on FCC certification. Users can also download software and drivers and get tech support. Site transforms hobbies into cash Jameco Electronics has introduced its new Club Jameco Web site (www. ClubJameco.com), where electronics do-it-yourselfers can design kits for hobbyists and earn royalties. The site lets designers create an electronics project by identifying components, MACHINE DESIGN.com writing step-by-step instructions, and selling the creation as an electronics kit. A “crowd-source” feature lets members comment and contribute to the project while it is being designed. Projects will be sourced, built, promoted, and sold without any cost or risk to the designer. Club Jameco also lets electronics enthusiasts discover, discuss, develop, and purchase electronics kits. Enclosures catalog The new North American Edition of Rittal Corp.’s product catalog is available in electronic or print versions. Nearly 900-pages long, it covers the company’s IT and industrial products from large security enclosures and mobile data centers to junction boxes, stainless-steel enclosures, and the nuts and bolts required to assemble accessories. Get a copy at www.rittal-corp.com/literature. Sensors site Balluff has launched a new Web site on the company’s inductive, photoelectric, vision, capacitive and magnetic sensors, as well as linearposition transducers, RFID systems, and networking products. The site includes product data sheets, support material, and literature. Product selectors let users apply physical, environmental, electrical, and specialduty attributes to identify the mostsuitable product for a design. Learn more at www.balluff-usa.com. AUGUST 9, 2012 FREE WEBINARS ON SENSORS, PROCESS CONTROL AND MORE Take 30 to 45 min and watch free Webinars on industrial controls topics. Whether live or prerecorded, see equipment in action and gain some insight. SENSORS This short, 30-min session will review all types of sensors, including: photo, proximity, fiber optic, magnetic, capacitive, ultrasonic, light curtains, and more. We will cover real-world applications and take live questions. August 15, 2012, 2:00 p. m. ET PROCESS CONTROL This prerecorded 40-min presentation discusses process control, and the products that are useful in those applications. Learn about devices that can sense temperature and pressure; control devices such as temperature controllers and PLCs that accomplish PID control; signal conditioning; and timer relays that are useful in this area of automation control. PNEUMATICS This prerecorded 40-min session covers the NITRA pneumatic product family. The line now includes stainless-steel cylinders, filters, regulators, lubricators, solenoid valves, position switches, tubing, and fittings. See working demos and customer examples. Visit www.automationtalk.com to check the schedule and register for upcoming presentations, or view the prerecorded Webinars on demand. Solutions you can trust. Brands you can trust. Rex® Falk® Link-Belt® Thomas® TableTop® Rexnord solutions are not just about a transaction. To support your business, Rexnord delivers what’s needed to run a successful operation, including: t Dependable product availability and on-time delivery t Innovative solutions for a broad range of applications t Respected brands supported by sales, training and technical expertise 866-REXNORD www.rexnord.com RS# 106 MatTop® Marbett® RTS® Rexnord provides a comprehensive line of products and services: t Bearing t Coupling t Gear t Industrial Chain t Conveying Equipment t FlatTop t Installation, testing, maintenance and repair EDITORIAL Risks, benefits, and mental mistakes You are reading our annual energy issue which looks at promising advances that could change the way we live. It is fair to say that certain energy technologies, particularly in the renewable area, have large, vocal followings. So we were intrigued by recent work from psychologists who found that many people make decisions about technology using emotions and mental shortcuts. Interestingly, people doing this generally don’t recognize their thought process isn’t strictly rational. The research results ring true partly because researchers stayed away from politically charged technologies such as energy. Headed up by University of Oregon psychology Professor Paul Slovic and East-West Center Senior Fellow Melissa Finucane, the research group surveyed people’s opinions about various topics such as water fluoridation, cars, and food preservatives. They asked subjects in the study to list both the benefits and risks of each technology. All in all, the researchers found people based their judgment about a technology on their feelings for it. People rated those they liked as having large benefits with little risk. When commenting on technologies they didn’t like, they could only think of disadvantages; few strong points came to their minds. It wasn’t just the uninformed public who were prone to such black-andwhite assessments. Professionals making judgments in their field fell victim to them as well. In one case, members of the British Toxicology Society found few benefits in substances they thought were risky, few problems with those they liked. There was a second part to Slovic and Finucane’s study. Their group had respondents read brief arguments in favor of various technologies they’d just opined on. Some of the arguments focused on the benefits of a technology, others stressed low risks. These short passages turned out to be effective at changing the emotional appeal of the technologies. People who read about the benefits of a technology also changed their mind about its risks; they perceived it as being less risky. A point to note is that the passage they’d read mentioned nothing at all about risks. In a similar vein, people only told that the risks of a technology were mild started to look at its benefits in a more favorable light. The way we feel about something also tends to make us ignore statistics even when we understand their implication. Researchers say our responses to uncertain situations appear to have an all-or-none quality that is sensitive to the possibility rather than the probability of strong positive or negative consequences. So events with very small probabilities carry great weight with most people. This, they argue, helps explains the impact of big headlines about hazards such as nuclear power and exposure to extremely small amounts of toxic chemicals, despite widely available information about the small probabilities of their feared consequences. It is not difficult to see how these conclusions pertain to the shrill public debates surrounding energy policy. People who have pet energy technologies don’t have to face painful trade-offs that are built into embracing them. Technologies we favor are likely to have few costs. Less favored technologies are all bad. In this ideal world, decisions are easy. — Leland Teschler, Editor 8 RS# 107 MACHINE DESIGN.com AUGUST 9, 2012 The widest product range in the shortest lead time. Scan this QR code* to learn more about Numatics Express * Requires QR code reader. Configure and order hundreds of FRLs — plus thousands of other products — shipped in 3 days or less. Numatics Express just increased its lead as the industry’s most comprehensive quick-ship program.To our long list of popular, high-reliability pneumatic valves and actuators with guaranteed 2-day shipment, we’ve added over 600 air preparation products such as filters, regulators, lubricators, and more! And don’t forget 3-day shipment of fully tested, assembled valve manifolds. All via our intuitive online configuration and rapid assemble-to-order capability. So OEMs shorten development/build cycles and accommodate last-minute changes, while end users slash MRO inventory and cut downtime. For the widest range of quality pneumatic products with the shortest lead times, call Numatics today! The Numatics trademark is registered in the U.S. and other countries. The Emerson logo is a trademark and service mark of Emerson Electric Co. © 2011 Numatics, Inc. 1-888-NUMATICS (683-2842) | www.numatics.com/express | e-mail: [email protected] RS# 108 EDITORIAL STAFF EDITOR Leland E. Teschler [email protected] MANAGING EDITOR Kenneth J. Korane [email protected] SENIOR EDITORS Leslie Gordon [email protected] Stephen J. Mraz [email protected] ASSOCIATE EDITORS Lindsey Frick [email protected] Robert J. Repas, Jr. [email protected] RS# 109 INDUSTRY COVERAGE: AUTOMOTIVE, PACKAGING, MEDICAL Stephen J. Mraz CAD/CAM, MANUFACTURING Leslie Gordon ELECTRICAL, ELECTRONICS Robert J. Repas, Jr. FASTENING & JOINING, MATERIALS Lindsey Frick FLUID POWER Kenneth J. Korane MECHANICAL Lindsey Frick Kenneth J. Korane EDITORIAL PRODUCTION Denise Greco Editorial Production Manager Randall L. Rubenking Art Director 1300 E. 9th St. Cleveland, OH 44114-1503 10 MACHINE DESIGN.com RS# 110 AUGUST 9, 2012 Lubriplate® The Essential OEM Lubricant Range... WHEN IT COMES TO SPECIFYING LUBRICANTS FOR ORIGINAL EQUIPMENT... Lubriplate® CAN MEET YOUR REQUIREMENTS. 5 142 Years of Lubrication Expertise 5 Factory Direct Representatives 5 Dedicated OEM Department 5 Vast Product Range - Both H-1 Food Grade & General Industrial 5 Worldwide Distribution Network Lubriplate’s Extended Life Air Compressor Fluids Include... SynXtreme AC Series – , # *# &'% &)!(!%#%!" (& Syn Lube Series – , *"''# * $# +"  & (& Synac Series – ,  &'% &*"'' % #!$%&&#% (& Syncool – , *"''# * *# &'% & #%   %" * #!$%&&#% ( SFGO Ultra Series – , && ##% *"''  & (& AC Series – ,'%# (! & "'%#%'+ #!$%&&#% & ,*-)#0#1 .'!0',+,)10',+/ RS# 111 Backed By: Lubriplate ® ESP Extra Services Package For more information contact Ellen Girard, LUBRIPLATE’s .(#0'+%+)4/0   5#%'..")1 .'-)0#!,* 5 ,*-)'*#+0.4)+01.2#4/5 #!&1--,.0 5 1 .'!0',+,$03.#5 Machinery Tags 5 ,)),3-1 .'!+0+)4/'/5 Training LETTERS The bright side of pessimism “Kennedy asked his fellow Americans to join him in a quest to end poverty, disease, tyranny, and war.” (“A Generation of Pessimists,” June 6). Asking someone to join in a quest does not mean the goal is attainable. Nor does it mean that because the goal is unattainable, one should not try to achieve it. It is not pessimistic to believe that these goals are unattainable, merely realistic. Given that human nature is involved, it is likely impossible to end all these things. Mike Stoneberg Maybe the reason the younger generation of students is pessimistic about the future is that they have a real understanding of the reasons behind global warming and are all too often faced with people who call them “environmental extremists.” Engineers should be working towards solving the real problem of global warming. They should be pushing for energy conservation and designing vehicles that reduce CO2 emissions. Too often the youth of our nation are faced with people such as yourself who are standing in their way. That’s a real cause of pessimism. Ed Malec Perhaps today ’s students are more obser vant than Horgan gives them credit for. Perhaps they are aware of the “success” of the various War on Poverty programs over the past half century, which demonstrate the inability of the government to solve or cure poverty. William Kelly The job prospects for many college students are terrible, while their debt levels are astronomical. These students could probably live with any of the world’s other 12 MACHINE DESIGN.com Reasons to be down R e a d e r s s e e m to s h a re the opinion that there are perfectly good reasons to be pessimistic, especially when it comes to the government’s ability to help anyone. They also seem pessimistic about geometrical dimensioning and tolerancing, an art or science few engineers have mastered. problems if they knew there was a decent job waiting for them. For example, my parents saw the horrors of World War II, but there was tremendous economic opportunity in the 50s and 60s and they quickly became optimistic, at least about their own futures. I feel that prosperity has been redistributed too much toward the top 1%. That redistribution was masked for a while by climbing debt, but now that bubble has burst. That’s the problem. Steve Oberheim Lack of experience in engineering college With over 27 years of designengineering experience, I’m still amazed at the lack of practical design knowledge being taught — even in the mechanical-engineering departments of major universities (“Working with Dimensional Tolerances,” May 10). It appears that most professors understand the math and science involved in engineering, as that is what they can test, but they are clueless when it comes to practical design methods. During the last several years, I’ve observed how several younger mechanical engineers have approached the machinists in our model shop. Some told the machinists: “Just do it the AUGUST 9, 2012 way I’ve designed it.” The result: parts that don’t fit, lots of rework, too much scrap, and a myriad of other issues that could have been avoided had the engineer only spent a little time learning how to interact with the shop personnel. These guys can — and will — be the friend of any engineer who treats them with respect. Insulting the shop personnel just cuts off the communication you need to understand how to redimension the part, or tweak the design for manufacturability — crucial items, if you want to move your career forward. Tim K. Ries This article makes it sound as if dimensional tolerances are optional. Not so. Every dimension on a drawing must have an associated tolerance, whether specific to that dimension, or covered by general tolerances in the title block. Lack of a tolerance precludes your ability to reject parts made to dimensions you can’t use. This is usually covered in Engineering Drawing 101. The fact t h a t m a ny e n gi n e e r s d o n o t understand this is indicative of many of the problems we face today in manufacturing. Vern Lowry I have been doing tolerance stack u p a n d d i m e n s i o n i n g fo r 3 0 All the Tools you Need for Embedded Measurements and Control, in one rugged box. Q Graphical Software Q Custom Triggering Q Sensor Connectivity Q Actuator Connectivity Q Signal Analysis Q Embedded Storage Q Control Algorithms Q Industrial Networks Q Custom Timing Q Expansion Systems The NI CompactRIO hardware platform can handle your embedded measurement and control applications, and do it in a way that outperforms other off-the-shelf systems so you don’t have to spend time developing a custom solution. The range of high-quality measurements, coupled with an extremely rugged design and the ability to modify the hardware using NI LabVIEW system design software, gives you all the benefits of customization with the convenience of an off-the-shelf platform. >> To learn more about CompactRIO, visit ni.com/compactRIO 800 891 2755 RS# 112 ©2012 National Instruments. All rights reserved. CompactRIO, LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 05312 LETTERS years. The problem in the industry is that everyone believes you can hire someone to snap a CAD dimension and throw it over the wall to manufacturing. Steve Washeim What goes around Your recent cover and associated article struck a responsive chord with me (“Better Alternatives for Wind Power,” May 10). I worked for one of the National Labs during President Carter’s uncoordinated lunge in the general direction of what we now know as green energy. Someone at another lab conceived the idea of harvesting the jet stream by flying kites that were conceptually, if not geometrically, similar to the one on your cover. That was in 1980. You might be amused to know that I drew a cartoon expressing my general skepticism about the concept. I titled it the Horizontally Oriented Wind Generator, Jet stream Oriented, With Lifting Surfaces. It was to be known by its acronym: HOWG JOWLS. Bob Woods Software upgrades that make things worse Poor design is also rampant in software (“Form Should Follow Function, and More,” April 26). The software companies think they know what you want, but then with each update (hardly an upgrade), they bury the tools you use 99% of the time under layers of “sales features.” This is how Google ruined their e-mail. I have to make extra clicks to sign out or find contacts. And why are there now six types of contacts to search? I just want one contact list. Microsoft also ruined Excel this way. Users now have to find the basic tools by digging through layers of new, mostly unused crap. Even Britannica succumbed. They pushed out fundamental reference data, their supposed bread and butter, to make room for the “news.” The CRC handbook took this same misguided route. They are all becoming tweets rather than tools. All these companies left out the first step in systems engineering when “improving” their software: Assemble the stakeholders, especially the users, and find out how they really use the tools. William Elrod One Stop Shop - Build to Print Shielding Solutions Next Day Delivery From Our Catalog ● Grounding Springs ●Ê - Ê «ÃÊ ●Ê iVÌÀÊ>ÃiÌà ●Ê Ý«>ÃÊ-ÌÊ>ÃiÌà ●Ê >À`ÊiÛiÊ-i`à ●Ê ÕÊiÊ-Ì>`>À`Ê*À`ÕVÌÊÊ Ê >ÃiÌÊ >Ì>} Download EMI/RFI Shielding Product Catalog at www.tech-etch.com/shield ,62 9,.0:;,9,+ TECH-ETCH, INC., {xÊ`ÀÊ,>`]Ê*ÞÕÌ]ÊÊäÓÎÈäÊUÊ/ Êxän Ç{Ç äÎääÊUÊ8Êxän Ç{È ÈÎ 14 MACHINE DESIGN.com AUGUST 9, 2012 RS# 113 Integrated Motion Solutions (Purchase Order to Shipment) Groschopp uses the Fast Track™ department to quickly build motors/gearmotors to meet customer’s demands. Because Groschopp stocks components rather than finished motors/gearmotors, we can easily make modifications to the motor/ gearmotor to meet your requirements. Modifications include: t t t t t t t t Various bolt hole patterns Face/foot mountings with special flange Shaft size/diameter/shape Special bearings and seals Terminal box Insulation Keyway Threading 48 HOUR Fast Track™ Gearmotors Because our Fast Track™ designs are based on standard product lines our experienced, on site machinists can quickly alter bolt hole patters, create custom shafts, threadings and more. After the entire build process is complete the Fast Track™ department has two rooms designated for testing the motors/ gearmotors. Computers and high tech testing equipment allow them to perform accurate tests on the hand-built motors. From there the motors are packed with the help of a sophisticated Styrofoam® packaging system. Need a few motors quickly? Submit your application specs at www.groshcopp.com/specs or call (800) 829-4135 and ask to speeak with a regional account manager. www.groschopp.com ISO 9001:2008 D QUALITY M FIE TI MENT AGE SY AN Phone Toll Free Fax Email CE R (712) 722-4135 800.829.4135 (712) 722.1445 [email protected] Connect with us: EM ST Groschopp Inc. 420 15th St. NE Sioux Center, IA 51250-2100 USA REGISTERED RS# 114 SCANNING FOR IDEAS Edited by Stephen J. Mraz Rotary actuator increases speed, rotation, and response while cutting costs To improve the speed and control of rotary actuators used in laser scanning and other optical systems, engineers at Pangolin Laser Systems, Orlando, Fla. (www.pangolin.com), decided to take matters into their own hands and designed a new rotary actuator. The result, the VRAD-1510 is reportedly capable of higher speeds, greater range of rotation, faster responses, and more-precise shaft movement than other Precision actuators. The low-power bearing Coil unit, which is based on an innovative dual-coil, segmented stator design, also Magnet costs about one-third less than existing rotary actuators. This means the device could be used in a End range of elecStator block tromechanical applications, including mechanical and automotive systems, robotics, HVAC, and Output valve control. Precision shaft bearing Pangolin designers developed a new and inexpensive way to make segmented stators without air gaps, which interfere with the motor’s magnetic field. The design also uses two, separately accessible coils, resulting in a compact, quiet, and durable actuator. For durability, the actuator uses a magnetic spring and preloaded ball bearings. the device flexible in terms of how it can be The unit also does not need mechanical used. For example, instead of using both stops on shaft rotation, which eliminates coils to generate torque, one can be used much of the noise, wear, and vibration. for dynamic braking or to sense velocity. The shaft rotates more than ±60° from Units can be configured to meet custhe neutral position. The actuator also has tomers specs in terms of torque factor, front and rear shafts, letting users add an magnetic-spring stiffness, coil resistance encoder or position sensor for closed-loop and inductance, shaft diameter and length, bearing preload, and operating temperaoperations, or other optional attachments. ture range. The rectangular shaped unit The VRAD-1510 features a linear remeasures 1.5 × 1.0 × 1.5 in. sponse. So applying twice the voltage gives RS# 401 twice the output angle; applying three times the voltage results in three times the r formation via ou output angle. Request free in Web site at ice rv Se er ad Re The actuator’s coils can be driven in sec design.com/rs ries, in parallel, or separately, which makes ww w.machine 16 MACHINE DESIGN.com AUGUST 9, 2012 COMPLETE ENGINEERING SOLUTIONS Start here. "The navigation and ordering process are easy to work. Thanks." – Richard, Newark element14 customer At Newark element14, all your engineering needs come together in one source—vast product range from world-class brands, fast online search, seamless purchasing tools, resources and services, one-on-one support, and a community of experts. Here, you’ll find simpler, smarter and faster ways to do business. HOW MAY WE HELP YOU TODAY? COMMUNITY: element14.com WEBSITE: newark.com PHONE: 1.800.463.9275 LEARN MORE: newark.com/together RS# 115 SCANNING FOR IDEAS Gear drives reliably transmit power Gear-drive units from Mitrpak, Uxbridge, Mass. (www.mitrpak.com), have proven reliable for power transmission for over 30 years in the mostdemanding applications. All of the drives, including right-angle, threeHardened high-alloy-steel spiral-bevel way, and counterrotating units, gears for high speed and loads, and give users mounting smooth, quiet operation flexibility, with each drive having several mounting flanges and body-mounting surfaces. Customers can also order special materials, shaft extensions, and other modifications. The durable drives use double-shielded, permanently greased standard metric ball bearings, as well as hardened-alloysteel spiral-bevel Metric, gears and aluminum doublehousings. Stainless-steel shielded, shafts are standard. The permanently Aluminum drives’ gear-meshing assembly lubricated housing for gives users quiet, vibration-free ball bearings strength and performance. And a bearing heat dissipation locknut makes maintenance in the field efficient and economical. Drives are shipped Bonded-lip grease seal, completely enclosed, sealed, recommended for use in and lubricated for life with food and drug industries Exxon Nebula EP-O. This grease withstands operating temperatures from –65 to 250°F. And bonded-lip grease seals provide positive grease retention, a feature recommended for food and drugCorrosion-resistant, handling equipment. Users can also specify stainless-steel shafts hardcoated housings and bearing locknuts for food-processing equipment. Hardcoating is an electrochemical penetrating process that prevents peeling and flaking. Bearing locknut lets users adjust for maintenance and Right-angle and three-way units range in weight meshing gears. from 2 to 20 lb, can handle inputs from 20 to 4,000 rpm, and transmit 26.3 to 630 lb-in. of torque. Counterrotating units weigh from 2 to 8 lb, handle inputs from 100 to 4,000 rpm, and transmit 22 to 189 lb-in. of torque. RS# 402 18 MACHINE DESIGN.com AUGUST 9, 2012
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